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cocorico D3sa rebuild
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cocorico
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July 29, 2013 - 7:41 pm
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Hello, as I'm no longer new and have the bike I'll transfer onto the rebuild threads.

The state of the bike on collection can be seen on 'Newbie' in 'Introduce yourself'.

On examination, it seems remarkably well preserved and not missing much, I think a lot of the preservation is down to a liberal coating of what seems a mix of dust and oil baked onto the engine and exhaust!

Right, to start:

I've removed and cleaned the carb - no obvious problems there.

Stator removed, all coils measure reasonably and the points look OK.

Engine gunked and pressure washed (carefully!) and now mainly clean.

Exhaust off, pipe is now clean, plating not bad; silencer stripped and baffles decoked, body soaking in diesel to help remove the coating (French term  - merde).

Inside tank looks OK, but I've swirled some diesel around and drained - no obvious rust, good flow from the tap (though it leaks a bit when shut - can't remove it yet).

I'll take some detailed pics of the baffles as they may come in useful later.

Think that will do for now - except I found an enamel badge on the rear mudguard - Elite Motors of Tooting were the supplying dealer.

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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BUSEY
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July 30, 2013 - 10:16 am
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Good luck with the rebuild my bike is in bits and lots of photos is always a good idea

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Peterg
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July 30, 2013 - 10:28 am
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Elite's were my local BSA parts supplier (along with Owen Brothers of Clapham Junction). I have many happy memories of going there to buy parts. They gave us a club discount unlike Owens.

Are you in touch with Steve Dunne? He ran a French BSA rally in May and knows quite a lot about Bantams.

 

The leaking tap can often be cured by taking the tap apart (remove the grub screw to release the spindle) and putting the cork end into boiling water. It is a matter of test it and see as you don't want it to expand too much. Smear it with Vaseline and put back. Avoid using vegetable (castor) oil as it absorbs moisture out of the cork.

Regards, Peter

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Blue Heeler
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July 30, 2013 - 10:41 pm
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If cork`s too far gone then new ones are readily available,I bought a packet full the other year and "put them somewhere safe"confused.Must get more organised.

Blue

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Katj
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July 30, 2013 - 10:46 pm
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Blue Heeler said
If cork`s too far gone then new ones are readily available,I bought a packet full the other year and "put them somewhere safe"confused.Must get more organised.

Blue

If you want to find them ... buy some more ... it always works for me doh

 

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mike p5xbx
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July 31, 2013 - 4:54 pm
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Peterg said

Elite's were my local BSA parts supplier (along with Owen Brothers of Clapham Junction). I have many happy memories of going there to buy parts. They gave us a club discount unlike Owens.
Regards, Peter

How long ago was that then i used to work for Owen bros on Saturdays and school holidays as a lad in the early 60s and built my first Bantam mostly from scrap parts found out back

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D? - D10- D14 Bantams 350 AJS -500 Triumph http://bsanotru.....lfire.com/

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Peterg
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July 31, 2013 - 5:41 pm
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Those were the days, climbing up the stairs to find Derek (I think that was his name) - a walking parts book!

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cocorico
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July 31, 2013 - 9:01 pm
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I've added pictures of the Major refurb to my account in ** Please log in to view **, there's also an album for the spare D1 engine I obtained with the AC only Wico-Pacy generator. I stripped that stator today, ign coil is open cct and the lighting coils had been cut. I've managed to reconnect the lighting coils, ign coil has a copper spring wiping connection to the HT lead - I assume a replacement coil is a solder job?

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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cocorico
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August 8, 2013 - 9:14 pm
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Should have given a better web address apparently.

Try:

** Please log in to view **

Latest news - removed the fuel tap, no rust or sludge on the filter, got the tap apart for a new cork.

Waiting for a few bits to enable a test start (HT lead, exhaust gasket).

Carb cleaned and jets blown through (107 / 80).

I also got a Dellorto 17.5mm carb off a French site very cheaply (lots of lads 'tuning' their mopeds) which fits the stub with the nylon liner removed, be interesting to try that.

Flushed out the gearbox ready for clean oil.

Must be patient and not start tearing things down!

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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cocorico
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August 12, 2013 - 4:24 pm
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I've reassembled the stator on the Major, set the points and timing (roughly) and now on kickover I can see a small spark at the plug and also an ac voltage on the output terminals, so things are looking encouraging for the electrical side.

Looking at the rear wheel, the riveted sprocket could be used to saw wood - as the bike came chainless I should obviously upgrade the sprockets to take a modern chain.

Question is, do I re-rivet the new sproc, or does it bolt on?

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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Cornish Rooster
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August 12, 2013 - 8:23 pm
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I have done some "experiments" with a Dellorto, you should be able to find the thread if you search. I tried quite a few combinations of jets and needles and on the last test the bike was really flying, well for a 150 Bantam anyway. I did have a bit of a misfire which I think may have been due to fuel airlock or partial blockage somewhere ? I too removed the nylon bush on the fixing and used a shim to get a good fit, at some point I will continue this project, I did have to fit a bell mouth on the carb as there was not any room got a filter .

Phil

BSA Bantam D1 "150" in use regularly often as general purpose transport, quite a few other bikes as well. Cornwall Area Rep. 

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baker man
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August 12, 2013 - 11:58 pm
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hi.. like the bike!..the way to go with your sprocket is to drill out the rivets, and use bolts to fit the new one..one of our lady members on this forum ( munchkin ) has done this very thing on her D1 this year....thumbs-up

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cocorico
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August 13, 2013 - 11:28 am
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Thanks for those replies, thumbs-up

I have seen your Dellorto thread Phil - looking forward to repeating your success.

Family over this week, so I won't be able to do muchwhistle

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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Sprung Chicken
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August 13, 2013 - 9:53 pm
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As Bakerman says,drill out the rivets then bolt it on. I've done this on mine,using a 420 chain & sprockets with allen bolts and nyloc nuts to secure the rear sprocket.

Dougie;Glasgow ;Scotland.
1955 D1, 1970 B175

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Piquet
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August 13, 2013 - 10:09 pm
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Yes, you can't use standard bolts with the original chains, the heads will foul the chain. There are special small headed bolts available, or, as Dougie suggests, use socket headed bolts.

Not sure if the same applies if you move to matching 420 sprockets and chain, but it wouldn't hurt to use socket headed bolts anyway.

I'm not a complete idiot ............................................ some parts are missing.

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cocorico
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August 23, 2013 - 10:23 am
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Family returned to Wales now, so I can resume some dabbling.

I just bought another lot of Dellortos from 'leboncoin' for about £30, ended up with a 17mm with manual choke, a 19mm ditto, another two bodies, a load of jets (75 to 125) and other odds and ends.

Looks like the easiest mounting option is the rubber tube, as it fits both the stub on the carb and that on the engine.

Need a visit from my Bro now to bring over some other bits I've ordered (pity some ebayers charge so much for postage to Europe).

No pics for the moment, as it's still as was, hopefully more soon.

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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cocorico
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September 5, 2013 - 10:54 am
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Hello all.

Not a lot of progress lately. I've had the front wheel out and cleaned and degreased the brake plate and drum, cleaned up the rim and spokes, which are in fairly good nick (even the underside of the mudguard still has the original grey paint, unmarked though muddy). There should be some odds and bits of spares arriving next week, so I might be able to see if it will fire up.

The most encouraging thing for me is that I've just got a document certifying it as a 'Vehicule de Collection', so I can get it registered over here now.

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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cocorico
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September 15, 2013 - 3:04 pm
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Some more progress.

I've got the new registration for the bike - so now I need to get it running.

Brother arrived for a week and bought some spares over with him.

I've now removed the engine from the frame to give it a clean and it's obvious that it's been out before as the frame is clean and the engine covered in c**ck. Also spotted that there appears to be a 'new' C piece for the centre stand, together with another home-made repair.

You can see on ** Please log in to view **

While the engine's out I'll check that centrestand (maybe treat it to a couple of walking stick rubbers), the shock absorbers and the rear wheel. I need some new engine mount bolts too, unless I go metric.

Still - coming on!

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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cocorico
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September 25, 2013 - 1:00 pm
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Wahey!

Engine back in the frame, new cork in the tap, tank back on, 19mm Dellorto fitted with 100 main jet, 60 choke jet, 55 idle jet, needle on notch 2, throttle valve 30, throttle stop 2 turns out, slow mixture 2 turns out.

Mixed some fuel (4% using a semi synthetic pre-mix oil).

Fuel on, choke on, no leaks apparent, kick over a few times and away she goes!

See the video on ** Please log in to view **

I've not had the engine apart at all (except the timing cover) and I don't know whether the sounds tell of impending doom!

Perhaps someone can tell?

Need to fit the throttle now, then sprockets and chain, new brake pads, etc, etc...

What fun, methinks a beer or two this evening! cheers

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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cocorico
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September 25, 2013 - 1:01 pm
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Sorry - link was wrong - try ** Please log in to view **

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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